System for diagnosis and remanufacturing of diesel injectors

Description

1 / 7 SYSTEM FOR DIAGNOSIS AND REMANUFACTURING OF DIESEL INJECTORS Technological Sector of the Invention

[001] The present invention pertains to the mechanical maintenance sector and relates to a system for diagnosing and remanufacturing fuel injectors and injector units of diesel vehicles, including heavy and light trucks, machinery, and utility vehicles. The system consists of a magnetic induction source to detect wear on internal components and an asymmetrical current source, which provides a controlled and adjustable power supply to accurately simulate the real electrical conditions of the injection systems. The asymmetrical source generates current pulses with specific waveforms, faithfully reproducing the electrical signals that the injectors receive in the engine, allowing the identification of electrical and mechanical faults with high precision. Unlike conventional direct current sources, its pulses are not symmetrical, as the activation and deactivation of the valves follow an electronically controlled dynamic behavior.The system enables functional testing without the need to install the injector in the engine, reducing time and operating costs. Furthermore, it allows for calibration, fine-tuning, and remanufacturing of injectors, ensuring that restored components operate within the required standards before reinstallation in the vehicle. Applicable to various types of diesel injectors, including Common Rail, UI (Unit Injector), and UP (Unit Pump) systems, the invention provides greater precision, reliability, and efficiency in remanufacturing, representing an economical and innovative alternative for the maintenance of these components. State of the art

[002] Remanufacturing fuel injectors and injector units is an essential process for restoring the functionality of these critical components in the diesel engine injection system. These components are responsible for supplying the exact amount of fuel to the engine cylinders, ensuring efficient combustion, optimal performance, and reduced fuel consumption. However, the Petition 870250013161, dated 02 / 18 / 2025, page 10 / 17 2 / 7 The remanufacturing process faces several technical and operational challenges that impact service quality and the reliability of recovered components.

[003] One of the main problems faced in remanufacturing is the difficulty in accurately simulating the real operating conditions of the injection system. Conventional methods often fail to reproduce the electrical and mechanical signals present in the actual operation of injectors, which can lead to premature failures and lower-than-expected performance. In addition, the diagnosis of defects in these components is often limited, making it difficult to identify electrical faults, short circuits, and internal wear of parts, which compromises the efficiency of remanufacturing.

[004] Another recurring problem is the wear and clogging of injectors due to exposure to fuels with impurities, which can lead to failures in the injection system and increase fuel consumption. Complete replacement of these components is extremely expensive, especially in heavy trucks and agricultural machinery, where the cost of a complete set can exceed R$ 60,000.00. Therefore, remanufacturing presents itself as a more economical solution, but its effectiveness depends directly on the technology employed in the process.

[005] Conventional equipment used in remanufacturing has significant limitations. Many of them use symmetrical direct current sources, which do not faithfully reproduce the electrical signals that injectors and injector units receive in vehicles, resulting in inaccurate diagnoses and inadequate adjustments. In addition, there is a wide variety of injection technologies, such as Common Rail, UI (Unit Injector) and UP (Unit Pump) systems, and many pieces of equipment available on the market do not have parameterizable adjustments that allow them to accommodate this variety of systems.

[006] Another problematic factor is that some remanufacturing methods require injectors to be tested directly in the vehicle's engine, a time-consuming and error-prone procedure, increasing operating costs and the risk of failure. Furthermore, the low precision in the adjustments of remanufactured injectors can... Petition 870250013161, dated 02 / 18 / 2025, page 11 / 17 3 / 7 compromise engine performance, leading to excessive fuel consumption, high emissions, and the need for additional repairs after installation.

[007] Therefore, the remanufacturing of fuel injectors and injection units faces significant technical challenges, mainly due to the limitations of the equipment available on the market. The lack of precision in simulating real operating conditions, the difficulties in diagnosing faults, and the lack of adaptation to different injection systems compromise the efficiency of the process. Given this scenario, there is an urgent need for innovative solutions, such as the use of asymmetric power supply systems, which allow for more precise simulation of the real operation of injectors, ensuring more accurate diagnoses, more efficient adjustments, and extending the service life of remanufactured components. New Invention Details

[008] The system for diagnosing and remanufacturing diesel injectors based on a magnetic induction source offers significant advantages for the maintenance and recovery of these essential components. The system operates by means of a magnetic field to detect the wear level of injector units and injector nozzles in trucks, buses, machines, vans and other diesel vehicles, providing an efficient and low-cost solution compared to the complete replacement of injectors. The high cost of replacing these components can reach R$ 62,500.00 for a large truck, making it unfeasible for many companies in the transport sector to keep their fleets fully operational without a significant financial impact. With the remanufacturing system, this cost is reduced to approximately R$ 6,000.00, representing a substantial saving that benefits not only the food transport sector, but the entire industry that depends on diesel vehicles.

[009] In addition to financial savings, the system offers operational and technical advantages that increase the efficiency and reliability of remanufacturing. It is capable of generating specific electrical voltage and current signals to activate Petition 870250013161, dated 02 / 18 / 2025, page 12 / 17 The system uses 4 / 7 solenoid valves and solenoids present in the injectors, allowing for a precise evaluation of component performance without the need for engine installation. This feature eliminates the complexity of traditional tests, reducing downtime and optimizing maintenance. The system also assists in the detailed diagnosis of electrical faults, identifying problems such as short circuits, actuation failures, and wear of internal components, providing greater accuracy in remanufacturing and ensuring that the recovered injectors function properly.

[010] Another major advantage of the system is its ability to test and adjust remanufactured injectors, ensuring they operate within the correct standards before installation in the vehicle. This significantly reduces the risk of post-repair failures and improves service reliability, avoiding rework and ensuring engines operate at maximum efficiency. Furthermore, the precision in simulating the vehicle's original electrical signals allows for fine-tuning of the injectors before assembly, providing better performance and reduced fuel consumption.

[011] The use of this system also results in significant savings of time and resources by eliminating the need for direct engine testing, which not only speeds up the remanufacturing process but also reduces the risk of further damage to engine components during conventional testing. With more efficient diagnostics and more precise adjustment, the system helps extend the lifespan of injectors, reduce operating costs, and ensure that vehicles remain in operation with optimized performance. Therefore, it is an innovative solution that meets the demands of the transportation sector, offering a more accessible, precise, and reliable method for diesel injector maintenance. Description of the attached drawings

[012] In order that the present invention may be fully understood and put into practice by any technician in this technological sector, it will be described as follows Petition 870250013161, dated 02 / 18 / 2025, page 13 / 17 5 / 7 in a clear, concise and sufficient manner, based on the attached drawings, which illustrate and support it, listed below: Figure 1 represents a photograph of the magnetic induction source; Figure 2 represents a photograph of the system components assembled. Detailed description of the invention.

[013] The system for diagnosing and remanufacturing diesel injectors consists of a magnetic induction source, responsible for generating a controlled magnetic field to detect wear and structural defects in injectors and injector units. In addition, it includes an asymmetrical current source, which provides specific electrical pulses to accurately simulate the real electrical signals of the injection systems. The system has test cables, used for the secure connection of the injectors to the equipment, ensuring precise communication between the components and the diagnostic unit.

[014] For dimensional analysis and necessary adjustments, the system incorporates a dial gauge with a magnetic base, used to measure minute displacement variations of internal components, and a caliper, which ensures correct calibration within the tolerances specified by the manufacturer. The system also includes grinding paste and grinding sandpaper, applied to restore the contact surfaces of the injectors, ensuring sealing and fuel flow efficiency. In addition, a tool kit for the injector unit is used for the safe disassembly and assembly of components during remanufacturing.

[015] The system has a control interface that allows parameterization and simulation of the injector's real operating conditions, ensuring that tests and adjustments are performed within the required standards. In this way, its constitution integrates different tools and devices that enable a complete analysis of the injectors, ensuring accuracy in diagnosis, efficiency in the remanufacturing process and reliability in the performance of the recovered components. Petition 870250013161, dated 02 / 18 / 2025, page 14 / 17 6 / 7

[016] The system operates in three main stages: diagnosis, adjustment, and final testing, ensuring that remanufactured injectors and injector units conform to factory specifications before their reinstallation in the engine.

[017] In the first stage, diagnosis, the injector is connected to the system via test leads, which activate the component's solenoids and solenoid valves. The asymmetrical power supply generates controlled electrical pulses, simulating the real conditions of the engine's injection system. During this process, parameters such as electrical resistance, current variation, and response time are analyzed, allowing the detection of faults such as short circuits, poor contact, internal wear, and injector actuation failures. The dial gauge with a magnetic base assists in verifying minimal displacements of internal components, ensuring greater precision in the analysis of mechanical wear.

[018] In the second stage, adjustment and remanufacturing, injectors identified as faulty undergo a reconditioning process. Grinding paste and grinding sandpaper are used to restore the contact surfaces of the internal components, ensuring proper functioning. Dimensional calibration is performed using a caliper, ensuring that the parts are within the tolerances specified by the manufacturer. The injector unit tool kit is used for disassembly and reassembly of components, ensuring that all parts are correctly reinstalled.

[019] In the third stage, final testing and validation, the remanufactured injector is reconnected to the system to verify its operation under simulated real-world usage conditions. The asymmetrical power supply generates specific electrical pulses to activate the injector, allowing for analysis of the component's behavior. During this test, the response time, fuel injection accuracy, and electrical behavior of the injector are evaluated. This process ensures that the remanufactured injectors operate within the required standards, eliminating the need for direct engine testing and reducing service time.

[020] With this structured approach, the system provides greater accuracy in diagnosis, efficiency in remanufacturing and reliability in final tests, Petition 870250013161, dated 02 / 18 / 2025, page 15 / 17 7 / 7 guaranteeing an innovative solution for the maintenance of diesel injectors and significantly reducing operating costs.

[021] It is important to emphasize that the figures and descriptions provided do not limit the ways in which the inventive concept now proposed can be implemented, but rather illustrate and make understandable the conceptual innovations revealed in this solution. Thus, the descriptions and images should be interpreted in an illustrative and not limiting way, and there may be other equivalent or analogous ways of implementing the inventive concept now revealed that do not fall outside the scope of protection outlined in the proposed solution. Petition 870250013161, dated 02 / 18 / 2025, pp. 16 / 17

Claims

1 / 1 CLAIM 1- SYSTEM FOR DIAGNOSIS AND REMANUFACTURING OF DIESEL INJECTORS, characterized by being constituted by a magnetic induction source, to generate a controlled magnetic field; an asymmetrical current source, which provides specific electrical pulses to simulate real electrical signals from injection systems; test cables, used for connecting the injectors to the equipment; a dial gauge with a magnetic base, used to measure minimal variations in the displacement of internal components, and a caliper, which performs the correct calibration within the specified tolerances; includes grinding paste and grinding sandpaper, for recovering the contact surfaces of the injectors; and a control interface for parameterization and simulation of the real operating conditions of the injector. Petition 870250013161, dated 02 / 18 / 2025, page 9 / 17

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